Pallet packaging and display assembly

ABSTRACT

A pallet packaging and display assembly for shipping products to a retail establishment and displaying the products in the establishment. The present assembly is particularly configured for shipping and displaying fresh produce, such as grapes. The assembly has retail package and pallet box components. The retail package is a generally box-shaped container having a transparent top section hingedly attached to a bottom section configured to hold the products. The pallet box has a base portion forming a cavity configured to removably receive a plurality of retail packages in a generally side-by-side relationship and a top portion configured to at least partially enclose the retail packages inside the cavity during shipment. The top portion can be a cover or lid to fully enclose the retail packages in the cavity. The consumer can selectively remove one or more of the retail packages from the pallet box for inspection and purchase.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 60/329,189 filed Oct. 15, 2001.

BACKGROUND OF THE INVENTION

[0002] A. Field of the Invention

[0003] The field of the present invention relates generally to packaging and display assemblies configured for shipping and displaying multiple quantities of individually packaged products. More particularly, the present invention relates to such assemblies and methods of utilizing such assemblies for economically shipping and displaying fresh produce, such as fruit and fresh vegetables, to and in a retail establishment.

[0004] B. Background

[0005] Many products are shipped in bulk containers from the manufacturer or producer of the product to retail establishments for sale to the consumer. During the process of manufacturing or producing the product for ultimate retail sale to the consumer, the products often go through a number of different packing and unpacking steps. A typical process involves multiple packaging and unpackaging of these same goods before it is purchased by the consumer. For instance, after the manufacturer or producer makes the product, it usually encloses the product in a package suitable for sale to the consumer (i.e., the retail package). The standard retail package is either intended to be visually attractive to the consumer or allow the-consumer to see into the package so that he or she may see the product and, thereby, be enticed into purchasing the product. In order to ship the products without damage to the packaging or theft of the products, the manufacturer or producer will typically place a plurality of these retail packages in a single larger bulk package suitable for safely, securely and efficiently shipping the packaged products to the retailer. At the retail store, the retailer must remove the individually packaged products from the bulk package in order to place the retail packages on the store shelves or other display stands where the consumer can view the products and, hopefully, purchase one or more of the products. Although bulk packages are typically discarded by the retailer, depending on the material used for the bulk package and the arrangements made with the manufacturer or producer, it may be returned to the manufacturer or producer for reuse.

[0006] The aforementioned method of packaging and shipping products is costly, both to the manufacturer or producer who has to initially package the products twice and to the retail establishment which must unpack the retail goods in order to place the products out for display to the consumer. In addition, with regard to certain items such as fresh fruit and vegetables, which are more subject to damage from handling during packaging and shipping, the systems that utilize this typical producer-to-retailer packaging can result in substantial lost product from being handled multiple times.

[0007] To avoid the costs and product losses from repeated handling, some products are packaged and shipped in bulk packages that can be reformed by the retailer into a display case or stand at the retailer's establishment. For instance, some bulk packages are suitable for reforming the package, either by cutting or tearing, to create a stand or other display assembly that the retailer can utilize in its store without removing the individual packages from the bulk package. By utilizing this type of packaging, the retail packages placed in the bulk package are not removed from the bulk package until done so by the consumer. In order for this type of packaging to be effective, however, the ultimate display assembly and presentation of the retail products inside the assembly must be appealing to the consumer so as to result in the desired sales activity. Naturally, the manufacturer or producer of the product must rely on personnel at the retail establishment to properly set-up the display assembly. By relying on the personnel at the retail establishment to open the bulk package and setup the display assembly, the manufacturer or producer loses control over the ultimate display of its product.

[0008] Recently there have been some new packaging solutions suitable for retail products that have combined the shipping and displaying properties discussed above. One such shipping and displaying assembly is described in U.S. Pat. Nos. 6,050,420 and 5,979,662 to Green, also the subject of design patent U.S. Pat. Nos. Des. 412,631 and Des. 353,092. These patents describe a shipping and display assembly having a display base for displaying a plurality of display packs, each having a product disposed inside, and a separate, removable shipping cover for protecting the assembly during shipping. The sides of the display base has multiple slots configured for receiving an edge of the display pack to hold the display pack in a generally vertical position. The display packs are placed into the display stand by the manufacturer of the product and covered with the shipping cover for shipment. At the retail establishment, the shipping cover is removed and the assembly is placed in the retail establishment for display.

[0009] To the best of the inventor's knowledge, none of the known packaging solutions have been applied to or have been suitable for fresh fruit and vegetables, particularly fresh grapes. For instance, these types of products are not generally suited for the vertical display systems of the Green patents. Fresh grapes, as an example, are typically packaged by the producer (i.e., a packing house) into plastic netting-type bags having a certain quantity of grapes therein, such as three or four pounds of fresh grapes. These bags are then placed into larger boxes, suitable for holding a number of such bags, for shipping to the retailer. Although the larger shipping boxes are generally suitable for protecting the grapes from shipping damage, they do not function well for display purposes. The retailer opens the shipping box and removes the bags of grapes so that it may place the netting-type bags on the shelves in the fresh fruit aisles of the stores.

[0010] For certain types of retail establishments, such as the warehouse-type stores that sell items in bulk quantities, the current process of packaging and selling grapes does not work well at all. In these stores, the boxes containing the grapes are shipped to the store on pallets and are placed in the store on the same pallets. Typically, the boxes (on the pallets) are merely opened and the grape bags are “displayed” to the consumer in the open box. The display that results is not generally very conducive to retail sales. As a result, there exists a need for an improved packaging and shipping assembly and method of using the same for shipping and displaying fresh fruit and vegetables, particularly fresh grapes, to and in a retail establishment.

SUMMARY OF THE INVENTION

[0011] The packaging and display assembly and method of the present invention overcomes the limitations identified above. That is to say, the present invention discloses a new and useful packaging assembly for both shipping and displaying quantities of separately packaged quantities of fresh fruit and vegetables, particularly grapes, in manner that allows securely, safely and efficiently shipping the produce and for easily and effectively displaying the produce at the retail establishment. The packaging and display assembly of the present invention substantially reduces the cost of handling such produce and reduces losses from mishandling.

[0012] In the preferred embodiments of the present invention, the pallet packaging and display assembly comprises a plurality of retail packages that are each configured to have one or more products disposed therein. In its preferred configuration, the packaging and display assembly is particularly beneficial for use with shipping and displaying fresh produce, such as grapes. The preferred container is a generally box-shaped container having a transparent top section hingedly attached to the bottom section with one or more connectors on the top section and one or more corresponding receivers on the bottom section for securely closing the retail package. The assembly also comprises a pallet box with a base portion and a top portion. The preferred base portion has opposing sides, opposing ends and a bottom configured to form a cavity for removably receiving the retail packages in a generally side-by-side relationship so as to form a single layer of retail packages in the pallet box. The top portion attaches to the base portion and is configured to at least partially enclose the retail packages in the cavity during shipping of the completed assembly. Preferably, the retail package also has one or more spacers to space the top section from the bottom section to improve air flow for the fresh produce. The top portion of the pallet box can be a lip member attached to the ends or the sides of the base portion and extending part way over the cavity, a cross-member attached to the base portion across the sides or ends of the base portion or a cover removably attached to the base portion and configured to fully enclose the retail packages in the cavity during shipment of the assembly. The cover can be in the form of a sheet of plastic material or lid member.

[0013] The packaging and display assembly of the present invention allows the producer or processor of the fresh produce to directly place the produce in a retail package suitable for displaying the produce and then place a plurality of those packages in a pallet box for shipping to the retail establishment. The pallet box is configured to contain and protect the retail packages and produce from damage during shipment. After the retail establishment receives the pallet box, all it has to do to prepare the produce for display is to remove any top cover or other protective member that is utilized and place the entire assembly on a pallet, shelf, table or other display device. The consumer can inspect the produce in the retail packages as they sit in the pallet box and remove the retail package from the pallet box for purchase.

[0014] Accordingly, the primary objective of the present invention is to provide a packaging and display assembly that overcomes the limitations heretofore associated with the presently available assemblies for shipping and displaying fresh fruit and vegetables, particularly grapes.

[0015] It is also an important objective of the present invention to provide a packaging and display assembly that holds a plurality of retail packages, protects those packages and the products stored therein during shipping and displays the products to the consumer.

[0016] It is also an important objective of the present invention to provide a packaging and display assembly comprising a pallet box configured to removably receive a plurality of retail packages having produce inside so as to protect the retail packages and produce during shipping and to display the produce to the consumer in the retail establishment.

[0017] It is also an important objective of the present invention to provide a packaging and display assembly suitable for shipping a quantity of produce to a retail establishment and displaying that produce in the retail establishment in a manner that allows the consumer to inspect the produce.

[0018] It is also an important objective of the present invention to provide a packaging and display assembly that is particularly suitable for use with shipping and displaying multiple packages of fresh grapes.

[0019] The above and other objectives of the present invention will be explained in greater detail by reference to the attached figures and the description of the preferred embodiment which follows. As set forth herein, the present invention resides in the novel features of form, construction, mode of operation and combination of processes presently described and understood by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In the drawings which illustrate the best modes presently contemplated for carrying out the present invention:

[0021]FIG. 1 is a perspective view of the separate retail package that is suitable for shipping and displaying the produce according to the present invention;

[0022]FIG. 2 is a side view of the retail package of FIG. 1 with fresh grapes disposed in the bottom section;

[0023]FIG. 3 is a perspective view of the pallet box suitable for shipping in pallet compatible groups and for containing and displaying the retail package shown in FIG. 1;

[0024]FIG. 4 is a top view of the pallet box of FIG. 3 with six retail packages of FIG. 1 disposed inside the pallet box;

[0025]FIG. 5 is a top view of a pallet box having an alternative top portion comprising a cross-member; and

[0026]FIG. 6 is a top view of a pallet box having an alternative top portion comprising a removable cover.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] With reference to the above figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth below. The retail package of the present invention, designated generally as 10, is suitable for receiving produce, such as grapes or other easily damaged produce, at the producer's facility, such as a packing house, and for displaying the produce to the consumer. The retail package 10 is sized and configured such that a plurality of such packages 10 will fit within pallet box 12, which is also used to display retail package 10 at the retail establishment, particularly those retail establishments that sell bulk or large quantity goods (i.e., warehouse-type stores) on pallets. The present invention combines the aspects of shipping and displaying produce into a single, less expensive assembly, collectively shown as 13 in FIG. 4, that is effective for packaging and shipping of the produce by the producer and for handling and displaying of the produce by the retailer.

[0028] As shown in FIGS. 1 and 2, the retail package 10 is a generally box-shaped container having a top section 14 and a bottom section 16 that are hingedly connected by hinge 18 along one edge of bottom section 16, preferably rearward edge 20. Bottom section 16 of retail package 10 is configured to be suitable for holding a quantity of produce 21 therein, such as grapes (as shown in FIG. 2). In the preferred embodiment, top section 14 and bottom section 16 are made out of a lightweight, transparent material suitable for use with fresh fruit and vegetables that allows the produce to at least be seen through top section 14 when it is closed against bottom section 16. Having a transparent top section 14 allows the consumer to see the produce 21 in retail package 10 even when it is displayed in pallet box 12. Although top section 14 and bottom section 16 can be two separate pieces, it is preferred that they are connected by an integral hinge 18 so that the producer, retailer or consumer can lift open top section 14 to look into or handle the produce 21, as desired or necessary, without risk of top section 14 being lost. As is well known in the produce and retail sales industries, consumers like to inspect by looking at and touching produce 21 they are considering purchasing to see if it is of a desirable quality. Integral hinge 18 allows consumers to do this without losing top section 14. As described in more detail below, retail package 10 should be shaped and configured such that one or more packages fit within the interior of pallet box 12 in a single layer, side-by-side relationship.

[0029] To securely close retail package 10, top section 14 has one or more connectors 22 on forward edge 24 for securely connecting to one or more corresponding receivers 26 on the forward edge 28 of bottom section 16, as shown in FIG. 1. In the preferred embodiment, connectors 22 protrude outwardly from bottom surface 29 of forward edge 24 and are configured such that they are received into receivers 26 with a snap-type action that securely closes top section 14 against bottom section 16 to prevent produce 21 from falling out of the package 10 during packaging or shipping. The consumer, as well as the producer or retailer, can open package 10 by lifting up on forward edge 24 of top section 14 to cause connectors 22 to release from receivers 26. In the preferred embodiment, package 10 also comprises one or more spacer elements 30 that are used to provide an airflow space between top section 14 and bottom section 16 when package 10 is closed (i.e., by use of connectors 24 and receivers 26 described above). Spacer elements 30 allow top section 14 to securely close against bottom section 16 but maintain a gap between top section 14 and bottom section 16 so that air can flow in and out of package 10. As is well known in the produce industry, produce 21 inside a container such as retail package 10 will last longer if cool air can flow in and warm air is allowed to flow out of the container. Although FIG. 1 is shown with spacer elements 30 on both top section 14 and bottom section 16, it does not have to be so configured. Instead, depending on the size of spacer elements 30, package 10 can have spacer elements 30 located on one or the other sections 14 and 16 and still provide a sufficient gap for air to flow in and out of retail package 10.

[0030] To provide structural integrity for retail package 10, sides 32 of bottom section 16 can have ribbed members 34 thereon to provide support for bottom section 16 when multiple layers of retail packages 10 are stacked on top of each other. As is known in the art, ribbing 34 can be made to be integral with sides 32 and be formed during the process of making bottom section 16. For further structural support, top section 14 can also comprise ribbing 36 formed integral with top side 38 of top section 14 so as to provide additional support for retail package 10 as it is stacked with other packages 10. Top ribbing 36 can be shaped and configured to interact with ribbing (not shown) on the bottom side 40 of bottom section 16 so that when multiple packages are stacked on top of each other they are not easily tipped or knocked over. To further improve air flow through retail package 10, top side 38 can also comprise one or more air holes 42. In addition, sides 32 of bottom section 16 can have one or more openings (not shown) in the form of holes or slots for air circulation. Bottom section 16 can comprise one or more drain holes 44 to allow liquid to drain out of package 10.

[0031] Pallet box 12 comprises a base portion 45 having sides 46, ends 48 and bottom 50 that form cavity 52, as best shown in FIG. 3. Preferably, pallet box 12 is made out of a lightweight, strong and relatively durable material, such as cardboard or various plastics. Pallet box 12 should be sized and configured to hold a plurality of retail packages 10 such that the packages 10 can be safely shipped and conveniently displayed in a side-by-side relationship (as shown in FIG. 4). For instance, cavity 52 of pallet box 12 should have dimensions that are only slightly larger than the size of the number of retail packages 10 that will be shipped therein to avoid undesirable movement of the retail packages 10 inside pallet box 12. Also, for most produce 21 it is preferred that the height of sides 46 and ends 48 be only slightly greater than the height of the retail packages 10 such that pallet box 12 provides cavity 52 that is only a single layer deep. Bottom 50 of pallet box 12 should be sufficiently strong to allow container 12 to be placed and moved on a pallet with a plurality of other containers.

[0032] Attached to or integral with base portion 45 is a top portion 54 configured to enclose or partially enclose the plurality of retail packages 10 inside pallet box 12. In a preferred embodiment, shown in FIG. 3, top portion 54 comprises a portion of upper edge 56 of sides 46 and a lip member 58 which extends inward from ends 48 to form an opening 60 into cavity 52. As shown in FIG. 4, lip member 58 holds retail packages 10 inside cavity 52 and yet allows the consumer to easily and without much effort remove retail package 10 from cavity 52 for inspection or purchase. With lip member 58 only at ends 48, the consumer can relatively easily remove a retail package 10 from pallet box 12 even when it is full of such packages 10. Naturally, after a retail package 10 is removed, removal of the other retail packages 10 in pallet box 12 will be easier. While the configuration for top portion 54 shown in the figures is the preferred embodiment, lip member 58 can extend all around opening 60 to more securely retain retail packages 10 inside pallet box 12. Alternatively, as described below, lip member 58 does not have to be utilized with pallet box 12.

[0033] Pallet box 12 should be configured to be stackable with other similarly configured pallet boxes 12. One way to accomplish this, shown best in FIG. 3, is through the use of one or more relatively stiff tabs 62 that extend generally vertically from base portion 45 at or near upper edge 56 and which are configured to connect with a corresponding slot 64 on bottom 50 of the base portion 45 of an above placed pallet box 12. Alternatively, slot 64 can be configured to be integral with ends 48, both tabs 62 and slots 64 can be integral with sides 46 of pallet box 12, or tabs 62 and slots 64 can be located on both sides 46 and ends 48.

[0034] In alternative configurations for pallet box 12 of the present invention, top portion 54 of pallet box 12 can comprise one or more cross-members 66 or a cover 68, as shown in FIGS. 5 and 6. In the preferred embodiment of these configurations, cross-member 66 and cover 68 should removably attach to base portion 45 so that the retail store operator can completely remove cross-member 66 or cover 68 for display in the retail store so as to allow greater access to the retail packages inside cavity 52. In this manner, the use of one or more cross-members 66 or cover 68 will protect and retain the retail packages 10 inside pallet box 12 while being shipped, but allow sufficient visibility and accessability to retail packages 10 in pallet box 12 when used for display. Alternatively, cross-member 66 or cover 68 can be attached at one side such that cross-member 66 or cover 68 is only partially removable (sufficient to allow access to and removal of retail packages 10). Cross-member 66 and cover 68 can be made out of the same material as pallet box 12 or other suitable materials. For instance, as shown in FIG. 6, cover 68 can be a sheet of transparent plastic material, such as plastic wrap, that can be folded back and removed from base portion 45. Alternatively, not shown, cover 68 can be made out of a solid cardboard or plastic material in the form of a lid type member that removably attaches to the top of base portion 45. Additionally, cover 68 can be used in conjunction with lip member 58 or cross-member 66 (i.e., over the top of these members to cover cavity 52).

[0035] In use, the producer of the fresh fruit or vegetables prepares the shipping and display assembly 13 by placing a quantity of produce 21 (i.e., three or four pounds of grapes) in a retail package 10 after the producer prepares the produce 21 in its normal manner. A plurality of retail packages 10, each containing the selected quantity of produce 21, are then placed into container 12 in a configuration such that retail packages 10 suitably display the produce 21 therein, for instance in the side-by-side relationship shown in FIG. 4. Pallet boxes 12 are then stacked on and secured to pallets or other shipping devices and shipped to the retailer. After receiving the pallet boxes 12, the retailer merely removes container 12 from the pallet or other shipping device and places the container 12, with retail packages 10 therein, on its retail floor in a manner that displays the produce 21 in retail package 10, such as placing the entire pallet box 12 on a shelf or table. If a cross-member 66 or cover 68 is utilized, the retailer removes, folds back or otherwise exposes the cavity 52 so as to make the retail packages 10 inside pallet box 12 more accessible. In this manner, the amount of handling of the fresh produce 21 is reduced and the retailer has a ready-to-display assembly 13 that allows the consumer to view and inspect the produce 21 before buying.

[0036] While there are shown and described herein certain specific alternative forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to the dimensional relationships set forth herein and modifications in assembly, materials, size, shape and use. 

What is claimed is:
 1. A packaging and display assembly, comprising: a plurality of retail packages, each of said retail packages having one or more products disposed therein; and a pallet box having a base portion and a top portion, said base portion having opposing sides, opposing ends and a bottom configured to form a cavity in said base portion, said top portion attached to said base portion and configured to at least partially enclose said plurality of retail packages in said cavity during shipping of the assembly, said cavity sized and configured to removably receive said plurality of retail packages in a generally side-by-side relationship forming one or more layers of said retail packages in said pallet box.
 2. The packaging and display assembly according to claim 1, wherein each of said retail packages is in a generally box-shaped configuration having a top section removably attached to a bottom section.
 3. The packaging and display assembly according to claim 2 further comprising a hinge interconnecting said top section to said bottom section of said retail package.
 4. The packaging and display assembly according to claim 2 further comprising one or more connectors on said top section and one or more corresponding receivers on said bottom section for securely closing said retail package.
 5. The packaging and display assembly according to claim 2, wherein said top section is transparent.
 6. The packaging and display assembly according to claim 2 further comprising one or more spacers on said top section or said bottom section to space said top section from said bottom section.
 7. The packaging and display assembly according to claim 1, wherein said one or more products in said retail package is fresh produce.
 8. The packaging and display assembly according to claim 7, wherein said fresh produce is grapes.
 9. The packaging and display assembly according to claim 1, wherein said cavity is sized and configured to securely receive said retail packages therein.
 10. The packaging and display assembly according to claim 1, wherein said top portion of said pallet box comprises a lip member attached to said ends or said sides of said base portion.
 11. The packaging and display assembly according to claim 1, wherein said top portion of said pallet box comprises a cross-member attached to said base portion.
 12. The packaging and display assembly according to claim 1, wherein said top portion of said pallet box comprises a cover removably attached to said base portion, said cover configured to enclose said retail packages in said cavity during shipment of said assembly.
 13. A packaging and display assembly, comprising: a plurality of retail packages, each of said retail packages having a top section removably attached to a bottom section and fresh produce disposed in said bottom section; and a pallet box having a base portion and a top portion, said base portion having opposing sides, opposing ends and a bottom configured to form a cavity in said base portion, said top portion attached to said base portion and configured to at least partially enclose said plurality of retail packages in said cavity during shipping of the assembly, said cavity sized and configured to removably receive said plurality of retail packages in a generally side-by-side relationship forming a single layer of said retail packages in said pallet box.
 14. The packaging and display assembly according to claim 13, wherein said retail package further comprises a hinge interconnecting said top section and said bottom section and means for securely connecting said top section to said bottom section.
 15. The packaging and display assembly according to claim 14, wherein said retail package further comprises one or more spacers on said top section or said bottom section to space said top section from said bottom section.
 16. The packaging and display assembly according to claim 13, wherein said top section is transparent.
 17. The packaging and display assembly according to claim 13, wherein said top portion of said pallet box comprises a lip member attached to said ends or said sides of said base portion.
 18. The packaging and display assembly according to claim 13, wherein said top portion of said pallet box comprises a cross-member attached to said base portion.
 19. The packaging and display assembly according to claim 13, wherein said top portion of said pallet box comprises a cover removably attached to said base portion, said cover configured to enclose said retail packages in said cavity during shipment of said assembly.
 20. A packaging and display assembly, comprising: a plurality of retail packages, each of said retail packages having a transparent top section hingedly attached to a bottom section and connecting means for securely connecting said top section to said bottom section, said retail package having fresh produce disposed in said bottom section; and a pallet box having a base portion and a top portion, said base portion having opposing sides, opposing ends and a bottom configured to form a cavity in said base portion, said top portion attached to said base portion and configured to at least partially enclose said plurality of retail packages in said cavity during shipping of the assembly, said cavity sized and configured to removably securely receive said plurality of retail packages in a generally side-by-side relationship forming a single layer of said retail packages in said pallet box.
 21. The packaging and display assembly according to claim 20, wherein said top portion of said pallet box comprises a lip member attached to said ends or said sides of said base portion.
 22. The packaging and display assembly according to claim 20, wherein said top portion of said pallet box comprises a cross-member attached to said base portion.
 23. The packaging and display assembly according to claim 20, wherein said top portion of said pallet box comprises a cover removably attached to said base portion, said cover configured to enclose said retail packages in said cavity during shipment of said assembly. 